Hi Johnny! 
I’m making the positive mold for the A-Pod body and abdomen. Starting off with a piece of lexan cut to the outline. I will build up the mold using modeling clay. Make a rubber mold off that, then create a plaster mold to vacuum form off of. What sort of modeling clay should I use?
Hi jim, really you can use any clay. i use Sculpey oven-bake clays. they are great for making nice clean edges and corners, so its a very versatile clay. it also keeps the mould clean. no need to bake it if you are just moulding from it. but for your idea i would think any clay will do.
if you use a wet clay ie earthenware clay, the best process would be to build up your sculpt and use plenty of water (applied with a soft sponge) to smooth it out. if a texture is needed i can talk you thought some cool texture tips. …wait for the surface of the clay to dry, dust off any excess dry clay powder that will form on the surface, otherwise this will bond with your mould. then you can mould it with your silicone rubber.
what silicone rubber will you be using?
Ok that makes sense. Not sure which type rubber compound I will use. Haven’t done much research. I will p/u some sculpey to experiment with.
here are some great casting/molding videos.
youtube.com/user/brickintheyard
I tend to use slightly different materials but the processes are the same.
any update Jim, im very interested to see what you have done.
I’ve got the Sculpey and the parts cut out to make the forms. Just not a lot of free time at the moment…
My first experience with Sculpey trying to make an A-Pod shell. I made a really lame lumpy thing. I’m trying something completely different. 
Lol. how about using a block of or layers of Balsa Wood.
this way you could sand it down to the desired shape and then vacuum form it?
or use Zenta’s idea for thermo-forming the body using a SES pattern positioning jig and ABS plastic?
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